Roll forming assembly

ABSTRACT

A bending machine has a pair of assemblies, each of which is in turn provided with a pair of counterpart dies. One of the dies is an elongated, stationary form. The other die is a train of progressive rolls mounted on continuous chains and movable along the form to gradually bend the stock of material to the shape of the form. Rollers for each roll engage corresponding backup rails during the bending operation.

United States Patent Gordon Herold Burke, Jr. Shawnee, Kane.

Apr. 23, 1969 Aug. 3 1 197 l Reed-Joseph Company Greenvllle, Miss.

Inventor Appl. No. Filed Patented Assignee ROLL FORMING ASSEMBLY I lClnlrns, 23 Drawing Flgs.

US. Cl

lnt.Cl. 821d 1/02 Field 214, 176, 178, US, 25,406, 320,

[56] References Cited UNITED STATES PATENTS 7 I 3,894 l H1902 MacFarren72/220 3,500,673 3/1970 Wheeler et a1... 72/220 Primary Examiner-MiltonS. Mehr AttorneySchmidt, Johnson, Hovey 8L Williams ABSTRACT: A bendingmachine has a pair of assemblies, each of which is in turn provided witha pair of counterpart dies. One of the dies is an elongated, stationaryform. The other die is a train of progressive rolls mounted oncontinuous chains and movable along the form to gradually bend the stockof material to the shape of the form. Rollers for each roll engagecorresponding backup rails during the bending operation.

PATENTED was] 19?;

SHEET 1 BF 3 INVENTOR Gordon Harold bur'kc Jr.

1 $3M as w @F JQ-IL D m 1 v8 v8 3 AM g 21 ATTORNEYS.

PATENTED m3] |97i SHEET 2 GF 3 INVENTOR Gordon Harold Burke Jr:

ATTOR NEYS.

PATEI'HEO was] :9?

SHEET 3 [)F 3 aw wk 9% INVENTOR Gordon Harold Burke Jn flliim 4" MATTORNl-IYS.

ROLL FORMING ASSEMBLY It is an important object of my present inventionto provide a bending machine for automatically bending stock materialsuch as sheet steel to desired configuration along its marginal edgesthrough use of trains of progressive rolls that act on a counterpartform so as to bend such edges into conformity with the shape of the formas the rolls are advanced by virtue of driving continuous chains towhich the rolls are attached.

Another important object of the present invention is the provision in amachine of the aforementioned character of a backup rail in spacedrelationship to the form and along which the rolls travel for holdingthe latter against the marginal edge of the sheet material as the rollsperform their bending functions.

Still another important object of the instant invention is to provideantifriction rollers for each roll respectively which engage the backuprail so as to permit free rotation of the rolls in the oppositedirection as they advance along the form with the bendable materialinterposed between the two counterpart dies, namely, the form and therolls.

A further object of my present invention is the provision of a bendingmachine capable of handling sheet stock of a wide variety of sizes andshapes regardless of whether the sheet material is in a flat conditionor bowed either transversely or longitudinally.

In the drawings:

FIG. 1 is a plan view of a roll forming assembly made according to mypresent invention, parts being broken away for clearness',

FIG. 2 is a fragmentary side elevational view of the assembly at one endof the latter;

FIG. 3 is a fragmentary plan view similar to FIG. 1 on an enlarged scaleat the opposite end of the assembly showing the wedge spacer;

FIG. 4 is a fragmentary longitudinal cross-sectional view of thestructure shown in FIG. 3;

FIG. 5 is a transverse cross-sectional view taken on line 5- 5 of FIG.4;

FIG. 6 is a fragmentary, enlarged, transverse cross sectional viewthrough one of the assemblies shown in FIG. I, illustrating one of therolls in section during its travel along the corresponding rail andform;

FIG. 7 is a view taken at right angles to FIG. 6 illustrating anotherone of the rolls in elevation;

FIG. 8 is a plan view of the structure illustrated in FIG. 7;

FIGS. 9-19 inclusive are fragmentary cross'sectional views illustratingthe eleven rolls of one of the assemblies;

FIG. is a perspective view of the finished article;

FIGS. 21 and 22 are plan views of two possible modifications of theshape and configuration which the stock material may take; and

FIG. 23 is an edge view of still another form of stock material.

The bending machine illustrated substantially in its entirety by FIG. Iis designated by the numeral 24 and includes a pair of elongatedassemblies 26 and 28 which are, for the most part, identical. Therefore,only assembly 26 will be described,

identical reference numerals being used for similar components in theassembly 28, followed by the letter 0.

Assembly 26 includes an open polygonal inner frame 30 and asubstantially identical outer frame 32, the frames 30 and 32 beinginterconnected by spaced horizontal crossbars 34. Assembly 26 isprovided with a pair of counterpart dies 36 and 38, the die 36 being inthe nature of an elongated form supported by the inner frame 30thereabove and in spaced relationship thereto by a plurality of posts40. In view of the nature of article 42 (FIG. 20) chosen forillustration, the form 36 has an L-shaped configuration presenting a topsurface 44, a side surface 46, a downwardly facing shoulder 48, alongitudinally extending, preferably rounded comer 50 between surfaces44 and 46, and a corner 52 between the surface 46 and shoulder 48.

The die 38 includes a plurality of progressive rolls designated by thenumerals 54-1 to 54-4] inclusive, each such roll having a groove 56therearound and being freely rotatable about an upstanding shaft 88through the medium of suitable bushings 60.

The shafts 58 are interconnected in a continuous train through themedium of an uppermost continuous chain 62 and a lower continuous chain64. Chains 62 and 64 pass around spaced sprocket wheels 66 at one end ofthe frames 30 and 32 and about a similar pair of sprocket wheels (notshown) at the opposite end of the frames 30 and 32, both of which arerigid to an upstanding shaft 68. Power means operably coupled with thetrain of interconnected progressive rolls 54 includes, as shown in FIG.2, a motor 70 coupled with speed reducer 72 through belt and pulleymeans 74 together with belt and pulley means 76 operably interconnectingspeed reducer 72 and the sprocket wheels 66, all carried by the frames30 and 32.

The shafts for the rolls 54 are provided with end cups 78 that are inturn closed by caps 80 held in place by fasteners 82. Certain of thelinks of each of the chains 62 and 64 are attached to the caps 80 byfasteners 84.

Each of the rolls $4 is embraced by an upper roller 86 and a lowerroller 88 rotatably mounted on corresponding shah-t 58 between the cups18 through the medium of bearings 90. The rollers 86 and 88 rotate alonga rail 92 in a direction opposite to the direction of rotation of therolls 54, the rail 92 being spaced from the form 36 and being carried bythe crossbars 34 through the medium of posts 94.

The rail 92 has a longitudinal upstanding plate 96 engaged by the outerperiphery of the roller 88, and plate 96 has a longitudinally extendingbar 98 engaged by the outer periphery of the roller 86. Rail 92 includesan upper longitudinally extending plate 100 that is engaged by theuppermost inclined marginal edge of the roller 86 and a lower plate I02that is engaged by the downwardly facing inclined marginal edge of theroller 88.

The blank stock I04 of bendable material such as sheet steel is clampedto the top surface 44 of the form 36 by a T-bar 106 that is coextensivein length with the form 36 and shifted to and from the positionillustrated by full lines in FIG. 6 by a fluid pressure piston andcylinder assembly I08 suitably supported by the frames 30 and 32 forswinging movement about a horizontal axis toward and away from the rail92. Any number of the assemblies I08 may be provided for actuating theT-bar I06 and the pistons I10 of the assemblies I08 are pivotallyconnected to a crank I12 that is in turn rigid to a shaft 114 rotatablycarried by the plate I00 of rail 92. An arm I I6, also rigid to theshaft I I4, carries the T-bar I06 through the medium of an adjustablebolt and nut assembly I18.

The assemblies 26 and 28 converge toward a hinge which interconnects theframes 30 and 30a for movement of the assemblies 26 and 28 toward andaway from each other upon operation of an interconnecting screw I22 atthe opposite ends of the frames 30 and 30a. Movement of the assembly 26during actuation of the screw 122 is facilitated by virtue of aplurality of rollers 124 which support the assembly 26.

A wedge I26 for supporting and holding the blank stock I04 is supportedby the assemblies 26 and 28 therebetween adjacent the hinge I20. Wedge126 is transversely T-shaped as shown in FIG. 5 and the forms 36 and 360are complementally grooved so as to support the wedge I26. A bar I28reciprocably carried by the wedge 126 has a handle I30 and a locater pin132, the latter of which is received by a hole I34 (FIG. 20) in theblank stock I04. Machine 24 is provided with a plurality of wedges I26of differing sizes and shapes depending upon the angularity between theassemblies 26 and 28 as adjusted by the screw 122.

The blank stock 104 also rests .on a crosspiece I36 having adjustableend sections [38 that are in turn provided with pins that extend intobrackets I42 and 1420 rigid to the forms 36 and 360 respectively.Croapieee 136 has a pair of upstanding pins 144 that are received bylocater holes 146 (FIG. 20) in'that end of the blank stock I04 oppositeto the hole I34.

Chain tightener wheels I48 for chains 62 and 64 swingably rr'sed by therail 92 are interposed between idlers I50 for the ter stretches of thechains 62 and 64.

In operation. when the rolls 54 and 540 are disposed as awn by fulllines in FIG. I the flat sheet of blank stock I04, ving a substantiallytriangular configuration. is laid on the rfaces 44 and 44a of the forms36 and 360 respectively with 2 pin I32 extending into hole I34 and withthe pins I44 exiding into the holes I46. Thereupon the assemblies I08are mated to shift the stems I10 upwardly from the dotted line sitionshown in FIG. 6 so as to swing the cranks I12 ickwise viewing FIG. 6.thereby rotating than 114 and inging the arms I16 to the full lineposition shown in FIG. 6, :reby bringing the T-bar I06 into engagementwith the ink stock I04, clamping the latter tightly against the top sur-1 :e 44 of the form 36. Although not illustrated in FIG. I, the

lernbly 28 is likewise provided with the same clamping sans for holdingthe blank stock I04 against the top surface a of the form 360. Suchclamping therefore cooperates with e pins I32 and I44 in holding theblank stock of bendable sterial I04 in place during the bendingoperation.

The motor 70 is then energized to circulate the chains 62 d 64 therebymoving the dies 54 successively around the aft 68 to the dotted lineposition shown in FIG. I. Sirnulneously, or later, the motor 70 fordriving the sprocket seels 66a is energized so as to circulate thechains 62a and la in the same manner.

As shown in FIG. 9, roll 54-1 is the first to engage marginal lge I52 ofblank stock I04 to commence bending it iwnwardly and inwardly around thecorner 50 toward the de surface 46. The rolls 54-2 to 54-8 inclusive areso shaped shown in FIGS. I0 to I6 inclusive as to gradually bend thesrginal edge I52 against the side surface 46 as such rolls l-2 to 54-8successively engage the marginal edge I52 durg the travel of the rolls54 along the form 36 from the apex 1d of wedge I26 toward screw I22.

Thereupon roll 54-9 moves into engagement with the lwerrnost extremityof the marginal edge I52 as shown in [0. 1'! commencing to bend itaround the corner 52 of form 6. Roll 54-10 continues the bendingoperation and finally the all 54-", by virtue of its configuration,completes the bendlg operation by forming a flange I54 against thedownwardly Icing shoulder 48 of the form 36.

The rolls 54 and 54a pass around the sprocket wheels 66 ad 664,returning to the full line position shown in FIG. I, the rotor 70 andthe corresponding motor for assembly 28 being eenergized by switches I56and 1560 carried by the frames 2 and 32a having actuator arms (notshown) that are tripped y suitable protuberances on chains 62 and 62a.

The assemblies 108 are then actuated to retract their stems I0downwardly thereby swinging the cranks II2, the arms I6, the assembliesII8, and the T-bar 106 to the dotted line osition shown in FIG. 6.Manifestly, the T-bar (not shown) or the assembly 28 is retracted in thesame manner to release he finished article 42 from the form 360.

The material from which the article 42 is made is suffiriently flexibleto permit slight upward deflection so as to elease the article 42 fromthe pins I44 whereupon, through we of the handle I30. the article 42 canbe slipped from the sums 36 and 360 as the bar I28 is pulled outwardlyin a Iireetion away from the base end of the wedge I26.

Noteworthy is the fact that while the rollers 86 and 88 'otate along therail 92 there is adequate space between the oil: 54 and the form 36 toreceive the marginal edge I52 as rbove explained and as illustrated inFIGS. 9-19 inclusive. On Lhe other hand, the necessary forces to beexerted on the marginal edges I52 by the rolls 54 and 54a are adequatelybacked up by the rail 92 by virtue of the engagement by the rollers 86and 88 with the plates I00 and I02 and by the similar rolling engagementbetween the roller 86 and the bar 98. plate 96 functioning in the samemanner with respect to the lower roller 88.

The length of the finished article 42 may be chosen within the overalllength of the assemblies 26 and 28', therefore. each of the forms 36 and360 will be provided with a plurality of spaced brackets I42 and therewill be provided a number of alternately used crosspieces 136, dependingupon the length of the article 42 to be bent. Moreover, the selection ofthe necessary bar 128 will depend also upon the adjustment of the screwI22 which in turn depends upon the width of the article 42 and theangularity of the marginal edges I52.

It is to be understood additionally that the outermost extremities ofthe marginal edges I52 need not be straight as indicated in FIG. 20. Themachine 24 will accommodate a blank stock 158 as shown in FIG. 2I havingconcave edges I60 simply by shaping the side surfaces 46 and 46a offorms 36 and 360 so as to present a counterpart convexity and byproperly shaping the rail 92 so as to guide the rollers 86 and 88 alonga path of travel complements! with the shape of side surface 46. Stillfurther, machine 24 may be made to accommodate blank stock I62 as shownin FIG. 22 having convex longitudinal edges I64 simply by proper shapingof the forms 36 and 360 as well as the rails 92 and 920.

Finally, a blank stock I68 may be bent at the marginal edges thereofwhen the blank I68 is longitudinally arched as shown in FIG. 23.Modification of the machine 24 in such event would necessitate the topsurfaces 44 for forms 36 and 360 having a longitudinal convexity with,of course, the rails 92 and 92a properly shaped in accordance with thearcuate configuration of the blank I68.

Having thus described the invention, what is claimed as new and desiredto be secured by Letters Patent is:

I. In a bending machine:

a pair of counterpart dies,

one of said dies comprising an elongated form,

the other of said dies comprising a train of interconnected progressiverolls for gradually bending a marginal edge of a stock of bendablematerial to the shape of the form during advancement of the rolls alongthe form and as the rolls are brought into successive engagement withsaid edge;

power means coupled with said train for advancing the same;

releasable means for holding the stock with said edge disposed in thepath of advancement of the rolls; and

an elongated roll backup member extending along and spaced from saidform for maintaining said edge clamped between the form and the rollsduring advancement of the latter,

each roll respectively being provided with structure engaging the memberduring said advancement for maintaining the rolls spaced from themember.

2. In the invention of claim I wherein the rolls and their structuresare separately rotatable about common axes intersecting said path.

3. In a bending machine:

a pair of counterpart dies,

one of said dies comprising an elongated form,

the other of said dies comprising a train of interconnected progressiverolls for gradually bending a marginal edge of a stock of bendablematerial to the shape of the form during advancement of the rolls alongthe form and as the rolls are brought into successive engagement withsaid edge;

power means coupled with said train for advancing the same;

releasable means for holding the stock with said edge disposed in thepath of advancement of the rolls; and

an elongated roll backup member extending along and spaced from saidform for maintaining said edge clamped between the form and the rollsduring advancement of the latter,

each roll respectively being provided with structure engaging the memberduring said advancement for maintaining the rolls spaced from themember,

the rolls and their structures being separately rotatable about commonaxes intersecting said path,

each structure including a pair of rollers having the correspondingrolls therebetween.

4. In the invention of claim 3 wherein said member is provided withroller-engaging means for holding the rolls against axial movement.

5. In the invention of claim 3 wherein said train includes a pair ofspaced, endless chains having the rolls and their rollers disposedtherebetween, there being a shalt interconnecting the chains for eachroll respectively about which the rolls and the rollers rotate.

6. in a bending machine. a pair of elongated assemblies, each including:

a pair of counterpart dies.

one of said dies comprising an elongated form,

the other of said dies comprising a train of interconnected progressiverolls for gradually bending a marginal edge of a stock of bendablematerial to the shape of the form during advancement of the rolls alongthe form and as the rolls are brought into successive engagement withsaid edge;

power means coupled with said train for advancing the same; and

an elongated roll backup member extending along and spaced from saidform for maintaining said edge clamped between the form and the rollsduring advancement of the latter.

said assemblies being disposed for supporting the stock thereacross.

there being releasable means for holding the stock with op posedmarginal edges thereof in the path of advancement of the rolls of thecorresponding train.

7. in the invention of claim 6; and means for shihing said assembliesrelatively toward and away from each other to adjust the same inaccordance with the dimensions of said stock.

8. In the invention of claim 6, said assemblies converging as one endthereof is approached, adapting the same to accommodate stock havingmarginal edges which converge as one end of the stock is approached.

9. In the invention of claim 8; and means for shifting said assembliesrelatively toward and away from each other to adjust the same inaccordance with the dimensions of said stock.

l0. In the invention of claim 6, said releasable means include pin meanscarried by the assemblies adapted to receive locater openings in thestock.

II. In the invention of claim 10 wherein is provided an element forremoving the bent stock from the forms, one of the pin means being onsaid element.

1. In a bending machine: a pair of counterpart dies, one of said diescomprising an elongated form, the other of said dies comprising a trainof interconnected progressive rolls for gradually bending a marginaledge of a stock of bendable material to the shape of the form duringadvancement of the rolls along the form and as the rolls are broughtinto successive engagement with said edge; power means coupled with saidtrain for advancing the same; releasable means for holding the stockwith said edge disposed in the path of advancement of the rolls; and anelongated roll backup member extending along and spaced from said formfor maintaining said edge clamped between the form and the rolls duringadvancement of the latter, each roll respectively being provided withstructure engaging the member during said advancement for maintainingthe rolls spaced from the member.
 2. In the inVention of claim 1 whereinthe rolls and their structures are separately rotatable about commonaxes intersecting said path.
 3. In a bending machine: a pair ofcounterpart dies, one of said dies comprising an elongated form, theother of said dies comprising a train of interconnected progressiverolls for gradually bending a marginal edge of a stock of bendablematerial to the shape of the form during advancement of the rolls alongthe form and as the rolls are brought into successive engagement withsaid edge; power means coupled with said train for advancing the same;releasable means for holding the stock with said edge disposed in thepath of advancement of the rolls; and an elongated roll backup memberextending along and spaced from said form for maintaining said edgeclamped between the form and the rolls during advancement of the latter,each roll respectively being provided with structure engaging the memberduring said advancement for maintaining the rolls spaced from themember, the rolls and their structures being separately rotatable aboutcommon axes intersecting said path, each structure including a pair ofrollers having the corresponding rolls therebetween.
 4. In the inventionof claim 3 wherein said member is provided with roller-engaging meansfor holding the rolls against axial movement.
 5. In the invention ofclaim 3 wherein said train includes a pair of spaced, endless chainshaving the rolls and their rollers disposed therebetween, there being ashaft interconnecting the chains for each roll respectively about whichthe rolls and the rollers rotate.
 6. In a bending machine, a pair ofelongated assemblies, each including: a pair of counterpart dies, one ofsaid dies comprising an elongated form, the other of said diescomprising a train of interconnected progressive rolls for graduallybending a marginal edge of a stock of bendable material to the shape ofthe form during advancement of the rolls along the form and as the rollsare brought into successive engagement with said edge; power meanscoupled with said train for advancing the same; and an elongated rollbackup member extending along and spaced from said form for maintainingsaid edge clamped between the form and the rolls during advancement ofthe latter, said assemblies being disposed for supporting the stockthereacross, there being releasable means for holding the stock withopposed marginal edges thereof in the path of advancement of the rollsof the corresponding train.
 7. In the invention of claim 6; and meansfor shifting said assemblies relatively toward and away from each otherto adjust the same in accordance with the dimensions of said stock. 8.In the invention of claim 6, said assemblies converging as one endthereof is approached, adapting the same to accommodate stock havingmarginal edges which converge as one end of the stock is approached. 9.In the invention of claim 8; and means for shifting said assembliesrelatively toward and away from each other to adjust the same inaccordance with the dimensions of said stock.
 10. In the invention ofclaim 6, said releasable means include pin means carried by theassemblies adapted to receive locater openings in the stock.
 11. In theinvention of claim 10 wherein is provided an element for removing thebent stock from the forms, one of the pin means being on said element.